Product Service Bulletin:

ACPSB9
Uploading AC Truck Event
Data Using wPTU
Oct. 24, 2003
Ken Nedley, Tim Brown

These instructions do not purport to cover all details or variations in equipment or to provide for every possible contingency to be met in connection with
installation, operation, or maintenance. Should further information be desired, or should particular problems arise which are not covered sufficiently for the
user’s purposes, the matter should be referred to GE. An applicable Federal, State, local regulations or company safety or operating rules must take
precedence over any instructions given in this material. GE has no obligation to keep the material up-to-date after the original publication.
THERE ARE NO WARRANTIES OF ACCURACY, MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.

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 I. DESCRIPTION:

The purpose of this Service Bulletin is to provide a procedure for uploading AC

truck system Event Data to a laptop computer. It also details where the data is
stored so it can be accessed and then emailed for offsite troubleshooting. The
Appendix contains a general description of the fault system for AC trucks.

II. DOCUMENTS REQUIRED:

None.

III. PARTS REQUIRED:

None.

IV. SPECIAL TOOLS REQUIRED:

Item # Item Description Part #

1 Laptop Computer running AC wPTU wPTU v2.01

2 Serial Communication Cable x
Standard 9 pin RS-232, male / female
end

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 V. PROCEDURE:

1. Record DID Panel Event Code(s).

A. Record the DID panel Event Code(s) you are interested in (including the
sub ID). The DID panel is located in the truck cab and the newest Active
Event will be displayed on it. If there is more than one Active Event, the
function keys must be used to access the other Event Codes.

Example: Code 12-1 Bad Retard Pedal.

2. Determine Event Data Location Based Upon Code.

A. PSC Event Codes

1) Codes 1-99, PSC Event Codes
2) Codes 100-199, INV1 Event Codes
3) Codes 200-299, INV2 Event Codes

B. TCI Event Codes

1) Codes 600-699, TCI Event Codes

Example: Code 12-1 data is located in PSC.

3. Connect Laptop and Run AC wPTU.

A. Connect the Laptop to the relevant CPU (PSC or TCI) RS-232 connector
using the serial cable based upon the Event Codes recorded off the DID
panel.

Example: Connect to PSC.

B. Run the AC wPTU and then “LOGIN to wPTU Toolbox” using the proper
password.

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 4. Access Event Summary Screen To Determine Date and Time.

A. On the side bar, under Special_Tasks, Event_menu, double click on

“PSC/TCI Event Summary”.

Example: Double click on PSC Event Summary

00521

Double click here.

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 B. Wait until the lower right hand corner message bar no longer says
“Retrieving Data, Please Wait….”.

00521

Wait until this message disappears.

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 C. Record the date and time of the Event you are interested in then close the
Event Summary screen.

Example: Event Code 12-1, record “24-OCT-03 11:32:04”

00521

Record “OCCURRED” info.

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 5. Access Data Pack Screen To Determine Data Pack Number (if it exists).

A. On the side bar under Special_Tasks, Event_menu, double click on

“PSC/TCI Data Packs”.

Example: Double click on PSC Data Packs

00521

Double click here.

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 B. Wait until the lower right hand corner message bar no longer says
“Retrieving Data, Please Wait….”.

00521

Wait for this message to disappear.

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 C. Match the Data Pack time and date to those you recorded previously, then
record the Data Pack number.

Note : The date format is different between the Event Summary Data Pack
screens.

Example: Event Code 12-1, 10-24-03 11:32:04, record “2”.

00521

Record “PACK #”

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 6. Upload Data Pack.

A. Click once on “Upload” at the top of the screen, then click once on
“Consolidated Truck Data Save”.

Click once here,

then once here.

00521

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 B. Click once in the “Event Summary List” box, then in the “Event
DataPacks” box, then type in the box below the number you recorded for
the Data Pack. (or if you have more than one, type in the numbers as
shown in the example below the box). Then click on “Begin”.

Example: Type “2” in the box.

Click once here,

then once here,
then type Data Pack number here.

Finally click once on “Begin”

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 C. Wait for the “Upload Complete!!” message to appear, then close the
Upload box.

Wait for this message to appear.

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 7. Laptop Directory Location Where Data Pack Information Is Stored.

A. The directory where the information you just uploaded is:

C:\Program Files\GEOHVPTU_201\data_ac

B. A new folder will have been created with the date and time of the
Upload. Truck number information will also be included.

Example: New folder is “00521_102403_1502”.

Directory

Truck number info. Date Time

C. Find the Upload folder and double click on it.

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 D. Three files will be included:

1) Event Summary
2) Data Pack Summary
3) Data Pack

Note: the Data Pack Summary is always Uploaded along with the Data
Pack.

The files can now be emailed for remote troubleshooting.

Note: The files can be “Zipped” before emailing. This will compress
them by more than 90%.

Example: Data Pack File is “PSC_Data_pack_02.ptu”.

Data Pack

Data Pack Summary

Event Summary

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 APPENDIX

A1. AC Truck Fault System Description

There are four CPU’s in the AC Truck Control System. The PSC or Propulsion System
Controller controls the power to the wheels while the TCI or Truck Control Interface
provides the operator interface for the system. There are also two inverter CPU’s which
take power commands from the PSC and derive firing commands to the inverters.

The PSC records faults generated in the PSC logic as well as those generated in the
inverter CPU’s. The TCI records faults generated in the TCI logic only.

System faults are defined as Events in the AC Truck Control System and there is a
summary of these Events stored in both the PSC and TCI CPU’s. One frame of data is
always recorded during an Event. This data is defined as Trigger Data and is the data in
the CPU when the Event was generated. Up to 300 Events with accompanying Trigger
Data can be recorded in each CPU. Once 300 Events are recorded, any new Event will
overwrite the oldest.

There is also multi-frame data that maybe recorded during an Event. This multi-frame
data is defined as a 5 second Data Pack. Each Data Pack can have up to 100 frames of
data which equates to 4.5 seconds of data before the Event was generated and 0.5 seconds
after. There is a limit of 30 to the number of Data Packs that each CPU can record and
there are three general rules for when one is recorded.

1. Recorded when there are less than 30 Data Packs presently recorded.
2. Recorded over the oldest Data Pack of the same Event but only if that Event has been
reset.
3. If several Events are generated at approximately the same time frame, only the first
Event in the chain will record a Data Pack. One frame of Trigger Data will then be
recorded for any Events that immediately follow.

An Active Event is defined as one that has not yet been reset. Active Event codes and
descriptions are displayed on the DID or Diagnostic Information Display panel in the truck
cab. The codes can be recorded off of the DID panel and then the relevant CPU can be
accessed to look for any data recorded. Note: the relevant CPU can be determined by the
Event Code number.

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Each CPU (PSC and TCI) can be accessed by running the AC wPTU program on a Lap-
top computer or the pocketPTU™ on a pocket PC. There are three separate locations
where Event data can be accessed while running either program which are:

1. Event Summary
2. Trigger Data
3. Data Packs

All of this data can be uploaded to your Laptop using the AC wPTU or pocketPTU.

There are two different Event Resets available in the system defined as follows:

1. Weak – Will reset Active Events. If the conditions that caused the Event are still
present, the Event will not be reset. (This avoids logging multiple Events of
the same # for the same occurrence of the Event). Events that have Locked
Out, cannot be reset using a Weak Reset.

Note: Events are Locked Out when they occur more often over a set time
period than a set number of times. Time periods and number of times vary per
Event.

2. Strong – Will reset all Active Events including those that have Locked
Out.

The Dump Override pushbutton in the Cab will generate a Weak Reset when depressed
with no truck motion. The system also performs a Weak Reset whenever the truck speed
transitions to zero.

The Reset menu on the DID panel can be used to generate a Strong Reset for individual
Active Events. (LIST -> RESET -> RESET * ). The wPTU or pocketPTU can also be
used to generate a Strong Reset for all Active Events.

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Figure A.1. provides a diagram for viewing and resetting system Events.

Figure A.1. View / Reset Events.

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